Apparatus for producing synthetic resin panels



Nov.. 24, 1976 R. I-LSONNEBORN ETAL 3,542,623

APPARATUS FOR PRODUCING SYNTHETIC RESIN PANELS original Filed April 4, 1963 5 Sheets-Sheet 1 INVENTORS RALPH H. 50AM/560ml. FERMA/00 11u/2 0f mL 00 BY POA/ILD Z BFL/ Arr-01PM.- Ys

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APPARATUS FOR PRODUCING SYNTHETIC RESIN PANELS original med April 4, 196:5 5 sheets-sheet a ENTORS '24,' 11.970 n. H.' soN-NEBORN ErAL- 3,5423234 APPARATUS FOR PRODUCING SYNTHETIC RESIN PANELS original' Filed April 4, 1965 4 srsneets-sheet s B POA/ALD?. 56H.

I Nov. 24,- 1970 R. H. soNNEBoRN :TAL 3,542,623

` APPARATUS FOR PRODUCING SYNTHETIC RESIN-PANELS Original-Filed April 4, 1963 l 5 Sheets-Sheet 4.

A fr0/PNE ya United States Patent O 3,542,623 APPARATUS FOR PRODUCING SYNTHETIC RESIN PANELS Ralph H. Sonneborn, Fernando Alvarez de Toledo, and

Ronald Z. Bell, Huntingdon, Pa., assignors to Owens- Corning Fiberglas Corporation, a corporation of Delaware Original application Apr. 4, 1963, Ser. No. 270,727, now Patent No. 3,291,672, dated Dec. 13, 1966. Divided and this application Aug. 9, 1966, Ser. No. 585,214

Int. Cl. B29g 5 00; B321) 31/12 U.S. Cl. 156-380 2 Claims ABSTRACT OF THE DISCLOSURE Apparatus for forming a continuous synthetic resin panel including a pair of spaced rolls providing a nip into which cover films, liquid resin and other components are fed under controlled conditions to provide a continuous lay-up which is converted into a rigid panel. An important feature is the retention of the resin pool within the Width of thel cover films.

This application is a division of copending application Ser. No. 270,727 filed Apr. 4, 1963, now Pat. 3,291,672 dated Dec. 13, 1966.

This invention relates to synthetic resin panels and method and apparatus for production. More particularly this invention relates to reinforced synthetic resin panels characterized by improved durability, weather-resistance and esthetic appeal; to a continuous process for producing such improved synthetic resin panels; and to apparatus for producing such improved synthetic resin panels on a continuous basis.

THE PROBLEM Prior panel As is well known, plastic panels or panels made from synthetic resins have been used rather widely in the years since their introduction on .a commercial scale following World War II. These panels have found rather extensive application for transparent closures such as windows and skylights; for interior decorative partitions or panels and walls; and as exterior screen fences, and the like.

It is well known, as evidenced by the volume of production of these panels, that at least in their original condition they impart an esthetic appeal to skylights, building partitions, patio walls, fences and other applications. Having a color or dye incorporated into the re'sin component, they are characterized by built-in color that is theoretically everlasting.

However, these prior products generally have been made with polyester resins, and exterior exposure has been devastating. Thus, under the effects of direct sunlight, rain and other weather conditions, etc., the prior panels have displayed extremely poor resistance to weathering. The weathering is characterized by rapid surface erosion of the resin causing fiber exposure and an extremely ugly appearance. Also, poor color stability has been evident from the decay in the vividness of color ina weathered panel as contrasted to a new unit. Thus, the prior products have exhibited extremely low resistance to ultraviolet light. These characteristic faults of the prior products are very widely known.

Also, in prior art products, exposed fibers collect dirt and industrial fumes; ruin the appearance of the panel; and invite further weathering causing a large'r drop in light transmission.

The foregoing changes, of course, take place over a period of from one to three years after installation. The result is a very unhappy customer when he realizes how ice much money and effort went into his original installation to provide such disappointing results.

The net result has been a bad reputation against the panel manufacturers. Further, the reputation of the glass ber manufacturer has suffered because many people conclude that glass fiber reinforced plastic panels are cheap" products.

It would, therefore, provide a substantial advance in the art if glass fiber reinforced synthetic resin panels could be produced that were of substantially improved durability against weathering; had good color stability and resistance to ultraviolet light; had high gloss retention; were characterized by high light transmission under all conditions of exposure including rain, sun, snow and others. It would also provide an advance to the `art if such panels had good gloss retention by being resistant to surface erosion; were thus resistant to fiber display or prominence, and thus exhibited greate'r esthetic appeal.

Prior production In the earlier days of reinforced polyester panels, hand lay-up batch operations were used. Curing was also by a batch operation, and this was effected for the most part in hot air ovens. In this operation, the wet resin lay-up was formed by laying down theI various elements as follows:

(l) Bottom cover film of cellophane or acetate;

(2) Reinforcement mat of glass fibers;

(3) Addition of liquid resin to saturate the reinforcement mat; and

(4) Top cover film.

The lay-ups were then placed on caul sheets and cured to provide rigid panels.

Gradually various continuous processes evolved, using the polyester resins and glass reinforcement in about the steps set forth above. One such process utilizes heated molds with the lay-up moved therebetween for shape for-mation. Due to the relatively mild exotherm of polyester resins, satisfactory production was effected; howe'ver, the products displayed low durability and extremely poor weathering. Also, this and most of the other processes have been characterized by resin runs in the panels, fiber washing, mold binding, air inclusion in the resin and others.

Thus a number of problems have beset those who have attempted to produce panels on a continuous basis even with polyesters. To our knowledge, there has been no commercially satisfactory process for molding and/ or curing panels having high durability, as from acrylic resins.

Accordingly, another substantial advance in theI art would be provided by a novel continuous method for producing panels of acrylic.

In this regard, a further substantial advance in the are would be provided by novel apparatus capable of continuously forming and then curing acrylic resin panels.

Other objects of this invention will appear in the following description and appended claims, reference being had to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.

THE DRAWINGS FIG. 1 is a general and partially schematic side elevational view of the important portion of apparatus of the present invention capable of forming and curing synthetic resin panels on a continuous basis;

FIG. la is a schematic representation of the process of invention;

FIG. 2 is a top plan view of the wet lay-up run out table and gel plate illustrating placement of tensioning rolls to maintain lay-up atness and to accurately guide the gelled lay-up into the forming molds;

FIG. 3 is an isometric detail view of a tension roll set;

FIG. 4 is an isometric section taken along line 4 4 of FIG. 2 illustrating the effect of the tension rolls in flattening the wet lay-up;

FIG. 5 is an enlarged section of the nip roll for-ming section, taken along line 5 5 of FIG. 2;

FIG. 6 is an isometric view of the nip roll section of FIG. l illustrating edge mastic application and liquid resin addition;

FIG. 7 is a plan view taken along line 7--7 of FIG. 5;

FIG. 8 is an elevation view along line 8-8 of FIG. 5;

FIG. 9 is -a side elevation of apparatus for forming reinforcement mat from raw fiber, at the head end of a machine typified by FIG. l;

FIG. 10 is a side elevation of apparatus similar to FIG. 9 but illustrating continuous laminate formation in accordance with the nip roll wrap characterizing FIG. l.

Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.

GENERAL INTRODUCTION The present invention is of three-fold aspect as follows:

1) Novel synthetic resin panels reinforced with glass fibers and characterized by a specific resin formulation and catalyst system, manipulated in specified manner for molding and curing; and the panels being characterized by improved weather resistance, color stability and greater esthetic appeal than analogous prior art products;

(2) The method of producing synthetic resin panels including:

(a) specific continuous formation; `and (b) continuous molding and curing and directly from formation and without interruption; and

(3) A production line capable of producing the improved panels of paragraph 1 on a continuous basis, with modifications including complete integration from fiber formation through mat development and on through finished resin panel ready for shipment.

In view of the foregoing, several novel aspects will be evident as the description develops, including the following:

(a) Acrylic resin systems utilized in a continuous process. These resin systems are characterized by the development of a relatively high exotherm of polymerization which is capable of boiling the monomer components if not carefully controlled. Further, these resin systems have a substantial affinity for air which therefore must be excluded at least from certain critical phases of the operation.

Therefore the present invention provides novel method and apparatus for handling these aspects of thes resin systems. Although within the broader scope of invention, the novel features developed here are understood to be applicable to other thermosetting resin systems.

(b) In the invention, unique mastic applicators are utilized to place a mastic bead along the edges of the wet lay-up. This serves a number of important functions including excluding air from the lay-up. Some resin systems dissolve air and do not release it during the exotherm of curing. Acrylics however appear to absorb air and then during the curing exotherm the air is driven out or released, causing blisters and snow defects which result in reject panels. This absorption appears to be a function of temeprature, and from room temperature to about 100 F. is quite high. Reversal at exotherm is disastrous to production, and the air -must therefore be excluded. This is unique with respect to acrylic resin systems, and accordingly handling this criticality in accordance with the invention provides novelty. This is effected through the sealing action of the mastic at the edge of the lay-up at the time of formation of the lay-up at the nip. The mastic then functions to prevent air entry during the remainder of the processing.

(c) A related problem regarding air inclusion in the laminate extends from the necessity of a uniform glassresin ratio. Even though air be excluded from the laminate, if resin rich areas are developed along the edges between the mat and the mastic bead, a boiled panel may result. This is due to the fact that the exotherm of pure resin is -more pronounced than the exotherm of the resinfiber composite. During curing, the pure resin exotherm being higher is directed into the edges of the laminate and causes a slight boiling along the edges. Accordingly, because the mastic substantially eliminates resin rich areas at the edges, this eXotherm of pure resin is prevented. Accordingly, the mastic provides a multifold aspect of:

(l) excluding air;

(2) reducing resin rich areas along the edge of the laminate;

(3) maintains edge thickness control; and

(4) provides more efficient resin utilization.

(d) Also, the manner of shipping the panel after initial cure or gel in the flat will become apparent.

In view of the foregoing brief perspective view, a complete and accurate description of all features of the invention will now be set forth.

THE RESIN SYSTEM AND CONTINUOUS PRO- DUCTION OF PANELS THEREFROM An advantageous resin and catalyst system that has been developed for use in the continuous process of invention utilizes a unique combination of peroxides, in-

cluding: (a) lauroyl peroxide; (b) methyl ethyl ketone peroxide; (c) tert-butyl peroxypivalate; (e) tert-butyl peracetate.

Thus, the complete resin and catalyst system includes the following ingredients in the proportions indicated:

Acrylic resin syrup (Du Pont Lucite #205)- parts Methyl methacrylate monomer-l0 parts Lauroyl peroxide-0.8%

Methyl ethyl ketone peroxide-0.16%

Tert-butyl peroxypivalate-0.72%

IIn addition to the foregoing, it is also to be included within the scope of invention to use either straight tertbutyl peroxypivalate or accelerator modified tert-butyl peroxypivalate as the catalyst. Thus, the following system would be included:

Acrylic syrup (Du Point Lucite #205 100 parts Methyl methacrylate monomer--IZ parts Tert-butyl peroxypivalate-0.5-1.5%

Still further, the fol-lowing system is to be included within the scope of invention:

Acrylic syrup (Du Pont Lucite #205)-100 parts Methyl methacrylate monomer-12 parts Tert-butyl peroxypivalate 0.5-1.5

Accelerator 6 (Du Pont product: organic and inorganic chlorides in methanol and higher boiling alcohols)- 1.25 X 10-4 CONTINUOUS PANEL FORMATION AND CURE By reference to FIG. 1 of the drawings, a side elevation will be observed of apparatus for the formation and curing of the novel synthetic panels of invention, both formation and cure being on a continuous basis.

THE VERTICAL NIP ROLLS The actual formation of the wet laminate or lay-up takes place at the left or entrance end of the machine, at the vertical nip rolls. These are designated by reference numerals 30 and 32 and are understood to be cylindrical steel rollers supported on suitable antifriction bearings at the ends. The bearings, of course, are mounted upon suitable support structures, not shown to avoid complicating the drawing. Y

It will be understood that the nip rolls 30 and 32 are optionally powered for a simultaneous rotation in a common direction at the nip as indicated by the arrows. Driving power is derived from a gear reduction motor 34 having a sprocket 36 on its output shaft 37. Sprocket 36 is aligned with a larger drive sprocket 38 connected to the shaft 31 of roll 30. A chain 40 laps sprockets 36, 38 for driving roll 30 from the motor 34. Adjacent sprocket 38 is a smaller sprocket 42. This is also carried on shaft 31 of roll 30 and is the same size as a corresponding sprocket 44 on shaft 33 of roll 32. Sprockets 42 and 44 are cross chained with a chain 46. Thus, when motor 34 turns in the arrow direction, the roll 30 is driven in the same direction, that is, toward the nip, and roll 32 is also driven toward the nip through the cross chain 46.

Another arrangement would be to gear the rolls tozether with a No. 5 pitch gear and drive one of them.

THE PANEL COMPONENTS The basic component of the panels of this invention includes an acrylic resin system, optional reinforcement and/01` filler materials can be included depending on whether structural or nonstructural, decorative applications are contemplated.

A typical reinforced panel would include the following:

Top: surfacing mat; Center: reinforcement mat(s), and Bottom: sunfacing mat.

These, of course, are impregnated and coated with resin that is cured into the finished product. During formation, these materials and the liquid resin are retained between top and bottom cover sheets such as cellophane or acetate, thus making a total of at least live layers in the lay-up during processing.

By reference to the left side of FIG. l, note that the bottom cover film is designated 48 and is fed from a stock roll 50 over a guide roll 52 to tangential contact with nip roll 30. The bottom surfacing mat is designated 54 and is fed from the stock roll 56 beneath guide roll 58 and then to tangential contact with nip roll 30 to overlie the bottom cover film 48. Next, the reinforcement mat is designated y60 and is fed from a stock roll 62 and around guide roll 64 and into tangential contact with nip roll 30 on top of bottom surface mat 54.

From the foregoing, it will be noted that the reinforcement mat 60 moves in a tangential infeed into a resin bath 66 maintained between the nip rolls 30, 32. The reason for this particular method of feeding and the advantages and inventive novelty resulting therefrom will be brought out in detail later.

It should be pointed out that the cover films in asreceived condition in the roll are not sufficiently smooth for processing through the system. Therefore, lateral tension is applied to the films, not to stress or stretch them, but instead to tension them to a good at condition.

It should also be pointed out that tension may be applied to the cover films to draw or feed them to and through the nip. However, the mats are carried or propelled into the nip in unstressed condition upon or by the cover films. Thus, forward motion without frictional drag or distortion of any kind is provided to advance the mats through the nip.

The top components of the wet resin lay-up include the top cover film 68 fed from a stock roll 70 beneath guide roll 72 and into top tangential contact with nip roll 32. Top surfacing mat 74 is fed from the stock roll 76 beneath guide roll 78 and into top tangential contact with nip roll 32 overlying top cover film 68. Note that there is also tangential entry of these top feed components into the resin bath 66, similar to the bottom feed components.

As the various mats 54, 60, 74 pass through the nip, they are impregnated with the liquid resin and are entrained between the bottom cover film 48 and top cover film 68 to form a Wet lay-up or laminate 80.

THE INSULATED RUN OUT TABLE-HUMIDITY COMPENSATION SECTION From FIG. l, it will be noted that the wet lay-up 80 proceeds downwardly from the forming nip and to the right, and is supported by a table 81 having a fiat top 82. This table 81 in the embodiment of the invention shown has the top made of fiber board material having a low heat transfer coefficient. Although it is within the scope of the invention to have the table top in the form of a heated plate structure, the present arrangement provides a more economical setup by utilizing a radiant heat source on only one side with loss of heat retarded from the table side.

Thus, an infrared radiant heater 84 is positioned above table top 82 and is directed to radiate downwardly on the wet lay-up 80. As will be brought out more fully hereinafter, this preheat section is used for the purpose of providing moisture control compensation to the cover films 48, 68 in accordance with existing ambient atmospheric humidity conditions. Thus, heater 84 is effective to reduce moisture content of the cellophane top and bottom cover films 48, 68 to a low level, so that exact tensions can be provided for retaining the lay-up in a flat, controllable condition for the subsequent steps of the operation.

Regarding this section, it is to be understood that the infrared rays from heater 84 penetrate the top cover film 68 and other components of the lay-up including bottom cover film 48 to gently warm the entire mass.

Since the resin system contains catalyst, the effect of the heat is to help initiate the exothermic polymerization reaction the resin goes through during the polymerization reaction.

It will be noted that the rays from heater 84 precondition wet lay-up 80, aiding resin wet out of the reinforcement and surface mats, and in general, preparing the wet lay-up for the next stage of operation.

THE GEL PLATE- GEL SECTION Looking back now to FIG. 1, note the gel plate which provides the first important physical (nonchemical) heating stage as regards kickoff or initiation of the resin polymerization reaction. The gel plate is designated by the reference numeral 100. This is essentially a fiat topped hot-water tank of rectangular cross section. Thus, gel tank includes the at top 102 of sufiicient body to resist sagging between its end supports; it may be suitably augmented by braces and baflies, not shown, to preserve flatness. The sides are designated 104, and the bottom 106. A waterproof structure is provided by welding the elements 102, 104 and 106. End closure is, of course, provided by end plates 108 designated in FIG. 1. The unit 100 is supported on legs 110 with cross stringers 112.

By reference to FIG. 1, it will be noted that tank top `102 is located at the same level as the top 82 of run out table 81. Thus, the wet laminate 80 slides along the production line on a level plane.

7 WATER FLOW 1N GEL SECTION By continued reference to FIG. 1, note that gel mold 100 receives warm water (100-150 F. for example) at its down stream end from a heater 114. Water ows from the outlet of the heater through line 116 into the down stream end of the tank 100 by connection at point 118. The water then flows upstream through the tank 100, i.e., against the direction of movement of the wet lay-up 80 over the top 102. Water exhaust from tank 100 is at point 120. This outlet comprises a line 122 secured in an outlet opening 124 at the upstream end of the tank 100. From the outlet opening 124, the return water ows through the line 122 and back to the inlet of the heater 114.

From the foregoing, it will be observed that the wet lay-up 80 is always advancing against a slightly increasing temperature gradient; it first encounters the cooler end of the gel tank 100 and proceeds toward the warmer end. Thus, the polymerization reaction, which is exothermic in nature, is kicked olf gradually or gently and is retained precisely in a controllable stage as it enters the forming mold section 128 after having acquired a proper gel condition. This gel condition and the reason for forming a gel will be more clearly brought out during a discussion of the actual molding stage following, but it is pertinent to state here that the gel is carefully controlled and exotherm is not permitted to run away. Thus, the gel platen 100 acts not only to kick off or initiate the resin polymerization reaction, but it also acts as a heat sink to absorb the heat of polymerization and thus precisely control the gel for the subsequent forming step. Note from the foregoing that the gel consistency is very precisely established and controlled to prevent or reduce running or ow during the contoured molding which follows.

It should be pointed out that a single gel platen is shown in the drawings and described above. However, operating conditions will dictate actual length of the gel section and temperature gradations to be maintained therein. Accordingly, the full scope of the invention will include plural gel platens, controlled to different and appropriate temperature levels.

Although not shown, a surge tank may be optional for use in the gel tank water flow system.

The gel lay-up is designated 125 in FIG. 1.

THE MOLD AND CURE SECTION By reference to FIG. 1, the bracketed section designated IV is the mold and cure section. This is characterized by matching top and bottom heated molds. In accordance with the present invention and the following description, it will be evident that a substantial degree of novelty is evident from this cooperative mold technique with control of the exotherm that takes place during the curing reaction which the resin undergoes.

THE BOTTOM OR FIXED MOLD First, it should be briey noted that the bottom mold is designated by the reference numeral 126 and comprises essentially a flat topped water tank. The top mold is designated by the reference numeral 128, and is suitably built in the form of an open top water tank. Between these units is a cooperating pair of caul sheets or mold plates.

The bottom mold 126 comprises a flat top tank generally similar to gel mold 100 but with a caul sheet of particular configuration separably held to the top for support and heat exchange purposes.

Water inlet and outlet openings are provided at each end of the bottom mold tank 126 for circulation of water; circulation will be described later by reference to FIG. l.

THE TOP OR FLOATING MOLD As mentioned before, the top mold is designated generally by the reference numeral 128. This is suitably an open top water tank. Water inlet and outlet is suitably pro-\ vided at each end by means of suitable lines, the one shown Cil being designated by the reference numeral 158, and being the inlet.

A note at this point will highlight the advantages which accrue from the use of a flexible metal sheet in the bottom of the upper mold. Thus, the metal sheet, in being shaped, provides a true cross-sectional dimension for the panel being produced. By virtue of the fact that the metal sheet can be adjusted laterally, in mated relation with the under mold, exact cross sectional control of the panel being produced can be maintained. Thus, peaks and valleys of the finished panel can be made highly uniform with the same thickness as the intermediate portions of the panel.

In general, this is a self-seeking or self-compensating operation automatically inherent in the structure of the top mold; this is brought about by the manner in which the top mold floats on and cooperates with the bottom mold.

An operational feature of the flexible metal sheet upper mold resides in the fact it can ride over hard gel portions which may occasionally arise in the lay-up by reason of improper amounts of constituents or improper constituents. Upon passage of such hard gel portions, the flexible sheet rides over and then again reinserts itself or conforms perfectly into the proper molding relation with the lower mold. Thus, there is no disruption of the process.

Further, the cover lms are not torn or ruptured by such gel particles because of the automatic compensation in the upper mold.

WATER FLOW IN MOLD SECTION Referring again to FIG. 1, it will be noted that fluid circulation through the mold system is as follows:

From a heater 162, water flows through an outlet connection via line 164 to an inlet connection 166 at the downstream end of the bottom tank 126. Water then flows upstream relative to panel movement and through an outlet 168. The line 158 is attached to outlet 168 and leads to the inlet end or downstream end of the top mold tank 128 for entrance as at the point 170. Water then flows from the downstream end of top tank 128 up stream of the direction of travel of the panel to be picked up by an outlet line 172 for return to the inlet of heater 162 for reheating. It will be observed that the open top tank 128 serves as a surge for the water circulation system.

MOLDING RECAP It may be observed at this point that the gelled lay-up is molded and substantially completely cured during its passage through the molds 126, 128.

It should also be pointed out that a novel feature of the mold stage is as follows. The mold tanks 126, 128 act in three ways:

(1) As heat input at the entrance to completely develop polymerization;

(2) As a heat sink back from the entrance end to control the resin against overheating atfer the exotherm is established; and

(3) A molding pressure medium to positively impart intimate mold contact and a desired configuration to the finished product.

DRIVING MECHANISM As the molded panel, designated by the reference numeral 206 moves out of the mold space, it passes between rotatable drive wheels 208. These wheels are covered with rubber to engage the upper and lower surfaces of the now rigid panel and grip the panel and pull it along providing propulsion from left to right of FIG. 1.

THE CURING OVEN After leaving the drive wheels 208, the panel passes through the oven 210 where it is post cured to a substantially completely polymerized condition. The effect of the post cure is to reduce residual monomer to a low level, about 1% or lower. This oven can be a hot air oven, however, an infrared oven is preferred because of uniform heating and penetration to the center of the panel. This tends to make the polymerization proceed from the center out and is believed to enhance surface nsh. Further, an infrared oven is preferred because of the fact that the entrance and exit mouths can be left open without appreciable energy losses.

This oven preferably operates at a temperature of about 280 F. when using acrylic resin systems.

An aditional effect of the oven is to relieve any molding stresses where the exotherm was relatively high.

The panel is thereafter designated 212, now being in a completely cured state just before a cut and pack operation. Auxiliary drive wheels 214 are provided at the exit end of oven 210. These provide the force necessary to push the fuly cured panel strip 212 through slitter saws off to the right. The panels are very tough and, accordingly, a substantial amount of force is required to feed it to an through the slitter saws.

The cut and pack section is designated by the reference numeral 216, and is only generally indicated because of the conventional slitter saws and transverse shears used therein.

Having provided a fairly detailed but general description, it is now believed that certain important processing details should be brought forth in the light of the foregoing discussion.

COVER SHEET TENSION CONTROL During prior discussion of the pre-heat or humidity compensation section, attention was directed to the infra red heater 84. This provided humidity compensation in the cover sheets 48 and 68 and warmed the entire wet lay-up in such manner as to let it atten. As the lay-up moves forwardly towards the end of run out table 81, lateral tension is gradually applied to assure flatness and proper forward feeding.

As shown in FIG. 2, opposed tension roll sets 218 are provided to grip the edges of the cover films at a position adjacent the exit end of run out table 81. At this point, it will suffice to say that each tension roll set 218 comprises an upper and lower ruber cover roll, canted as indicated relative to the line of movement of the wet lay-up 80. The edges of the cellophane cover sheets pass through the nip between each pair of rolls. Tension is thus applied in the general direction of the lines 220 to provide stretching all the Way from the forming nip roll 32, positioned just to the left of the infrared heater 84, FIG. 2.

At this point, reference is made to FIG. 3 to illustrate the general configuration of the tensioning roll sets 218. These comprise upper and lower elongated cylindrical rollers 224 and 226. These rolls comprise a steel shaft with a bonded tubular rubber coating to grip the cellophane cover sheets of the wet or gelled lay-up. The shafts are alike and are accordingly designated by the reference numeral 228. The exposed ends of shafts 228 are carried within bearings mounted in an arm 230. The housing 230 has a clamp portion 232 for mounting to an overhead post 234. Proper orientation of the rolls 224, 226 relative to the lay-up 80 is made by establishing the relation on the mounting post. A handle 236 adjusts running clearance.

By reference to FIG. 4, it will be noted that the layup 80 is gripped along the terminal edges outside of the mastic line 98 generally designating the approximate panel limit.

Referring again to FIG. 2, it will be noted that a set of tensioning rolls 218 also can be provided at the outfeed end of the gel plate 100 to provide tension along the stress lines 239 just prior to entry between forming molds 126, 128.

It should be pointed out that an important purpose of the side tension rolls is to compensate for forward processing tension.

10 THE IMPROVED WET LAY-UP FORMATION THROUGH THE VERTICAL NIP ROLLS WET OUT AND DEGASSING Referring to FIG. 5, note that the bottoni cover film 48, bottom surface mat l54 and reinforcement mat 60 are lapped over the top half of nip roll 30; thus a tangential entry of the mats into the resin 66 is provided. This is indicated by reference arrow 240.

Production line speeds are on the order of several inches to a few feet per minute. Rolls 30, 32 are of a prefered size in the range from 6 to 8 inches in diameter; thus, a slow and gradual entry of the inat components into the resin bath 66 is provided. Noting the resin liquid level line 242, it will be evident that the slow movement along tangential arrow entry line 240 permits the resin to force out all gases from the -mats 54, 60 along the line 244. Due to the relatively slow mat speed, the resin gently rolls around every fiber of the mats and thoroughly wets the bers. This produces complete degassing of the mats; further the action is so gentle as to prevent fiber washing. At higher speeds added monomer in the resin system and more readily soluble mat binder will enable the same effects to be provided.

Top surface film 74 at the upper right of FIG. 5 is also gently wetted and degassed in the same manner.

A further advantage is evident from FIG. 5. By virtue of the fact that the reinforcement mat 60` and bottom surface mat 54 half lap nip roll 30, they are gently fed or caried into the nip in unstresed condition as contrasted to being pulled by the forward movement of the cover films of the wet lay-up and subsequently by the cured panels. This provides a very gentle entry and wetting action and prevents distortion and abuse to any of the components making up the panel system. Adjustment of resin viscosity of course contributes to proper wet out.

RESIN APPLICATION Referring now to FIGS. 6, 7 and 8, resin application to provide proper ow and wetting without distortion of the mat will be described.

It will be noted that nip rolls 30 and 32 are of a length slightly greater than the total width of the cover lms 48 and 68. As best shown in FIG. 6, the mats 54, 60 and 74 are a few inches narrower at each edge than the cover lms. Between the edge limits of the cover ilms and the edge limits of the reinforcement and surfacing mats, there are provided mastic applicators designated by the reference numerals 246.

The resin pool 66 is formed between the limits established by the mastic applicators 246. These act as dams to retain the resin in the nip.

It has been found quite important that this resin pool 66 be maintained in a specific manner. Let us designate the length of the resin pool by the bracket reference numeral 248. Establishing the length of the resin pool 66 by the reference numeral 248, note that two resin lill nozzles 250 are provided at about one-fourth of the distance 248 inwardly from each of the mastic applicators 246. As better shown in FIGS. 16 and 17, points of resin application are designated by the reference numeral 252. By carefully observing the points of resin application 252, it will be noted that the resin deposited between or in the trough formed `by the nip rolls 30 and 32 moves in each direction laterally away from the points of deposition. By so operating, it has been found that only two entry points are necessary, thus providing flow for one-quarter of the length or width of mat formation and such ow being of such a gentle nature that washing of mat fibers and distortion of fiber lay in the mats is prevented. This provides most effective and economical resin application with minimum equipment.

A further important point relative to development of the resin pool is illustrated in FIGS. 5-8. Thus the nozzles 250 have the delivery ends submerged in the resin to de- 1 1 posit the resin below the surface without turbulence as might be developed by a stream dropping through the air. This prevents air pick-up, as previously pointed out, the presence of air in acrylic systems presents a serious problem. Thus one more aspect of the invention is provided for control of that factor.

In view of the foregoing, it will be noted that a resin flow at the nips is balanced, and no appreciable flow streams are present.

An alternate procedure for introducing the resin syrup into the nip to form a bath 66 is also illustrated in FIGS. 5-8. This comprises positioning the feed nozzles 250 upwardly from the nip over the top cover film. This is designated position 250(a), (250 alternate position).

With the nozzles 250(a) positioned just above the surface of the top film 68, the resin is deposited on the films as a coherent stream, i.e., without picking up air. The stream spreads into a thin film 250 (f) and fiows by gravity down the cover film 68 and into the pool 66 without turbulence.

This method is advantageous in two aspects:

(l) No air is picked up because of lack of turbulence of flow; and

(2) Any gas which might be present in the syrup is actually exposed and released while the resin is flowing in the film stage 250 (f).

It is to be understood that other methods of deposition than from the nozzles 250(a) can be utilized within the scope of invention. These however are relatively inexpensive, very practical, can be adjusted and cleaned easily.

The extreme detail with which the resin application has been described hereinbefore may appear burdensome to some readers. However, it must be understood that the resin is a relatively high viscosity material and picks up air readily. Thus careful deposition prevents fiber washing and air occlusion.

Therefore, the present invention depends for its success upon the correlation of several factors, among them being:

(a) Resin viscosity;

(b) Resins of a certain formulation and accelerator content;

(c) Resin application in a delicately controlled manner to prevent fiber washing and mat deformation; and

(d) The use of delicate surface mats to hold .resin at the surface and provide resistance to surface erosion; and consequently due to the delicateness of such surface mats to a carefully correlated manner of liquid resin application of specified viscosity.

AN INTEGRATED SYSTEM-FIBER FORMATION TO FINISHED PANEL It is within the scope of the present invention to attach a mat forming section to the front end of the machine shown in FIG. 1 and thus provide a completely integrated process from fiber formation to finished panel ready for shipment.

In the light of this brief introductory statement, there now follows a complete description of a completely integrated system showing varied modifications whereby the mat as itis formed can be applied in various modifications between the nip rolls for lay-up formation.

MAT FORMATION Referring to FIG. 9, it will be noted that the reinforcement mat is made from a plurality of strands each containing a plurality of continuous fibers.

More particularly, FIG. 9 illustrates a mat production unit 296 for making lofted mats from randomly interfelted strands of continuous glass fibers. The production unit 296 includes a plurality of continuous fiber forming bushings 298. Each bushing 298 includes a bodyportion 300, suitably fabricated of high temperature resistant platinum alloy. The alloy is also corrosion resistant to the glass being melted therein. Electricity is passed through the length of each bushing 298 by connection of suitable lead lines to end terminels, not shown. This provides resistance heating to glass melting temperatures of about 2000" F. and is controllable by regulating current flow to establish the proper glass viscosity for fiber formation.

Glass materials such as marbles, cullet or other are fed to each bushing 298 as by a top opening, not shown, t0 form a body of molten glass.

At the bottom, each bushing 298 is provided with a plurality (about 200) of aligned molten glass feed openings or tips 304. Molten glass from Within each bushing 298 flows through each tip 304 as a small molten stream 306.

When the streams 306 are drawn out or attenuated at high speed, they are reduced in diameter and converted into continuous raw fibers 308. These fibers are of a diameter in the range of about 15 microns and up.

Inasmuch as the mats used in the present invention are preferably substantially dry or binder free, the fibers are processed into mats as near the nascent state as possible. Accordingly, the raw fibers 308 are passed tangentially over a sizing belt 310. Belt 310 is moved through a liquid bath of size to provide application to the fibers. By the tangential contact provided by the belt 310, only a very light coating of size with a little lubricant is applied. No mat binder is employed. The size is just of a sufficient adhesive nature to hold the fibers together and provide appropriate strand integrity. However, it is to be emphasized that accelerator for the resin system can be introduced at this point.

The size is compatible with acrylic resin formulation described before, and thus is designed for optimum resin wet-out and minimum gas occlusion during wet lay-up formation at the nip rolls described hereinbefore.

From the sizing belt 310, the coated fibers converge downwardly over a guide block 312 and thus are directed into strand forrn 314.

Though not shown in detail, the belt 310 runs over a powered roll within a container 316 for the liquid size. The belt 310 also runs over a guide rod 318 positioned at the liber contact line. The container 316 is provided with liquid size at an appropriate level and from a suitable supply system. The guide rod 318 forms belt 310 into a sharp reversed curve for tangential fiber contact. This arrangement provides a highly effective wiping action for the liquid size from the belt 310 onto the fibers. The coated fibers are designated 320. Application of the size onto the fibers is in the form of a very uniform, but very thin, coating.

The strands 314 pass downwardly between the peripheries of corotating pull rolls 322. -Pull rolls 322 are mounted on the shafts of synchronous -motors 324. The pull roll action provides the attenuating force to convert the molten streams 306 to raw fiber 308.

The pull roll action also throws the strands 314 downwardly through the opening 326 in a support fioor and onto the upper flight 330 of a collecting chain To provide uniform strand distribution and even mat lay and uniformity, a reciprocating motion is induced into the strands 314. This is suitably effected by mounting the drive motors 324 for pull wheels 322 on a movable carriage 332. Carriage 332 is mounted on rollers 334 ridmg tracks 336. Along one side of the carriage 332, right side shown, is a toothed rack 338. A reversible gear motor 340 is mounted on floor 328 with its drive gear 342 engaging rack 338. Alternate reversing of the motor 340 is effective to reciprocate the carriage 332 a sufiicient distance for desired speed and throw of strands 314 onto collecting flight 330 for proper mat formation.

It will thus be understood that as pull rolls 322 are turned at appropriate speeds, are also reciprocated an appropriate distance across the width of collection llight 330, strands 314 are thrown downwardly in a random, ring-like fashion. 'I'hese deposit on collection flight 330 and simultaneously are distributed across the width of the flight. The mat is thus laid up in gradual increasing thickness 344 and moves to the right in the arrow 346 direction.

Collection chain 331 is a continuous loop supported by rotatable rolls 348. At least one of the rolls 348 is powered to move the chain 331 at an appropriate production line speed. At the right hand end of the collection flight 330, full thickness mat is developed, designated by the reference numeral 350.

A number of ramifications are evident in this mat forming system. Thus the end bushings can produce finer bers and in eiect form surfacing mats directly on each surface of a reinforcement mat, the latter being made of heavier fibers. Thus a unitary, triple component reinforcement surfacing mat can be produced for later processing.

'I'he full thickness mat 350 moves from collection ight 330 across to an accelerator application section 352. This section 352 suitably includes a continuous chain 354 supported on rolls 356, at least one being powered at production line speed. A suction box 358 is positioned beneath the upper flight 360. Above the left-hand end of upper flight 360 is at least one spray 362, for applying liquid accelerator composition.

This composition suitably comprises an innocuous liquid vehicle containing an appropriate amount of accelerator for the resin system. At this point, it is to be understood that the broad scope of invention would include application of powdered accelerator at this point by proper manipulation in an integrated manner with a slightly adhesive forming size-containing mat 350.

Also, it is to be understood that accelerator can be applied to the mat as it is being collected, as by the alternate nozzles 362. By operating in this manner, a very uniform distribution through all of the strands of the mat will be provided.

For the sake of clarity of the present description, however, lets presume application of a liquid accelerator system by spraying downwardly on the mat 350 from the spray head 362. To the right of the accelerator applicator 362 is an infrared heater 364. The purpose of infrared heater 364 is to lower the liquid level and reduce the composition to a sticky, gel-like stage. This provides optimum wet-out by the liquid resin applied later. This, of course, is optional and may be omitted when the air dry action of the suction box 358 reduces the accelerator liquid content to a proper resin wet-out condition.

Proceeding to the right from the accelerator application section 352, the accelerated mat 366 moves to a vertical nip set up similar to that previously described. Note that the bottom cover film 48 is fed into tangential contact with entry roll 30 and half laps that roll for delivery to the nip. The bottom surfacing mat 54 is also fed into tangential contact with the nip roll 30 and onto the top of the bottom cover film 48 for support.

Note that the accelerated reinforcement mat 366 moves in horizontally upon the bottom surface mat 54 and that both are supported and moved forward by the bottom cover film 48. Thus, no stress is applied to mats 54 and 366; stretching and distortion are avoided.

Resin application by nozzle 250(a) on the top cover film 68 is indicated at the right.

As indicated at 246, a mastic applicator is utilized to apply a mastic bead at each edge of the lay-up as it is formed and retain the liquid resin within bounds as it enters the nip rolls 30, 3-2.

From the point of completion at the nip between rolls 30, 32, the wet lay-up is designated 80, as previously, and from here on, processing is the same as described relative to FIG. 1. This includes cure in the very particular manner described as adapted to the particular resin system.

In this embodiment of the invention, note the tangential entry of the top surface mat 74 into the nip for proper wet-out and degassing, even though the wrap on. roll 30 is not quite as great as in FIG. 1.

TRUE VERTICAL NIP FORMATION-FIG 23 In still another embodiment, a full thickness mat 350 comes from a mat forming unit such as 296 of FIG. 9'. The mat 350 moves across flight 330 to flight 360 of chain 354 and traverses suction box 358 for accelerator application and set as at 362, 364.

In this embodiment, a hold down roll 394 is provided at the exit end of flight 360 of chain 354. Here, it will be noted the nip rolls 30, 32 are positioned higher than the flight 360 as contrasted to FIG. 22. This provides the same nip roll wrap as in FIG. l. In general, a slightly enhanced mat wet-out and degas is provided by this type of entry. The nature of this type of `wet-out is set forth fully above relative to the description of FIG. 14.

In view of the foregoing, namely, the various nip roll rarniiications of FIGS. 1, 5, 8, 9 and 10, a truly versatile system of wet lay-up formation is provided.

OPTIONAL ACCELERATOR In FIGS. 9 and l0, the accelerator is shown as being applied to the reinforcement mat 350. Admittedly, this provides the substantial ultimate in resin curing by the careful admixture of the accelerator with all parts of the resin. Further, this admixture in the resin is at the point of wet lay-up formation. Thus, an extended pot life for the resin is provided which otherwise is not the case as where the accelerator is applied either in whole or in part by premixing with the resin syrup.

As discussed in the early part of this description, the invention does include addition of accelerator to the resin at a premix station. This manner of operation is also possible with the apparatus and process of FIGS. 9 and 10. Accordingly, the accelerator spray 362 is merely shut down; however, the infrared unit 364 may be continued for cool weather operation or humidity control to condition the mat for improved resin wet-out.

MODIFIED PROCEDURE When operating in accordance with the flow system of FIGS. 9 yand l0, it may be desirable to reduce the heat input at the preheat stage II of FIG. l. This will prevent the resin polymerization from being prematurely initiated and the exotherm go wild before the heat sink provided by the gel plate is reached. Should this happen, resin lboil may be encountered. This will also prevent the gel stage for best molding from being exceeded with the result that the shaping provided by the upper and lower molds 126, 128 is retained.

THE METHOD OF THE INVENTION In FIG. la of the drawings, there is shown in schematic flow diagram form a recap of a principal part of the method for producing panels by this invention.

Actually, the process illustrated in FIG. la breaks itself down further into a two-fold aspect as follows:

(l) The method of producing the Iwet lay-up at the nip roll; and

(2) The method of continuously curing the wet lay-up by first bringing it to a gel stage or partial cure, and then subsequently molding after such partial or initial cure.

By reference to FIG. 1a, it will be noted that the various steps encompassing the foregoing aspects include those set out below.

Itis to be understood, of course, that the steps listed follow input material formation including reinforcement mat production directly from virgin fiber or otherwise, and the optional addition of accelerator to the mat as a -prelude to resin addition:

Step I: Wet lay-up formation at the nip rolls;

Step II: Running the wet lay-up through a radiation zone for humidity compensation of the cover ilm and conditioning of the other components;

Step III: Precure or gelling the wet resin lay-up by exposing it to a suitable temperature while sliding it across a at gel plate prior to running it into the mold. The purpose of this step is to set or gel the resin and maintain uniform panel thickness at all areas during molding. Thus, proper gel control retards the resin against running from the high points of the mold to the low points; this prevents thin spots.

Step IIIa: Initial shape development prior to molding;

Step IV: Molding and substantially curing the pregelled resin at suitable elevated temperature by pulling the gelled lay-up between upper and lower forming molds that act as a heat sink;

Step V Then moving the molded panel through an oven to provide full cure; and

Step VI: Thereafter processing the panels by cutting and packaging for shipment.

In light of the foregoing brief perspective view of the method of invention, a more elaborate description of each stage and the co-ordination of the stages of the process will now be provided.

Thus, by reference to FIG. 1, now note the various steps in proceeding through the following description.

STEP I-WET RESIN LAY-UP FORMATION AT NIP ROLLS By one apparatus or another, the reinforcement mats, surfacing mats and cover films are fed into a nip between two rolls in such manner as to provide tangential entry with good resin wet-out and degassing. An important aspect of the invention resides in the application of a mastic bead or ribbon along each edge of the lay-up to exclude air entry and prevent the liquid resin from running out of the cover lilms at the edges.

STEP II-HUMIDITY COMPENSATION AND CONDITIONING In as-received form, the cellophane cover sheets will have a variable humidity content. Therefore, in order to provide proper compensation and develop a controlled level of humidity for subsequent successful processing, the lay-up is radiated. This preshrinks the cover sheets to stable dimension. One way of doing this is to use a table and lamp according to FIG. l. This action is also helpful to precondition the resin for its entry into the following gel stage. Fiber wet-out is also assisted.

STEP III-PRECURE OR GEL As the wet lay-up enters the precure or gel stage, it is gradually heated from room temperature, about 70-90 F., on up to the gelling level of about 110 F. and up. Note that a heat sink assures proper control. Note further that initial cure is effected in the flat to provide uniform thickness throughout in later forming.

STEP IIIa-SHAPE DEVELOPMENT PRIOR TO MOLDING As pointed out in the prior discussion, shape development can begin to take place at the out end of the gel plate, thus prior to entering the molds. This is effected by gravity and optional floating sled weight. The purpose is to gradually shape the resin without imparting wrinkes to the cover lms.

STEP IV-MOLDING OR POST-GEL FORMING Next, the wet lay-up is gradually heated on up to a level not exceeding the boiling point of the monomer, about 214 F. Simultaneously, the mold pressures and forces are applied to shape and form the gel. The resin is now at full polymerization activity level, but still remains under precise control against exotherm runaway. This is effected by providing a heat sink all around the lay-up.

Thus, Step 4 reduces the resin to a hard stage and thus the thickness and shape of the panel are fixed.

STEP V-POST CURE The cured panels from Step 4 are next post cured and fully polymerized by a soaking period at about 250 F. for approximately 3-20 minutes. The panels are thereby fully completed and are directed to Step VI, following.

STEP VI-CUT, PACKAGE, ETC.

At Step VI, necessary cutting, shearing, stacking, packaging and shipment operations are effected to prepare the finished product for shipment to and use by the ultimate consumer.

EXTENDED SCOPE OF INVENTION Process variables The temperatures set forth in the foregoing description have been alluded to only in a general way. As a broad statement, stage II and III temperatures of lm conditioning and resin gelling will be in the range from about room temperature to about 185 F. Time and resin system will determine the specific temperature used, as all factors are correlated.

In general, the stage IV temperature will fall within the same range. In this state, the upper limit will be the boiling point of the monomer. This is about 214 F. Of course, this level must not be reached or the product will be ruined. Thus, room temperature to about 185 F. is suggested to provide a safety factor. Again, time and resin system are all correlated with temperature of processing.

In the post cure oven, stage V, temperatures in the range from about 200 F. to about 300 F. can be utilized, with a range of about 265-285 F. being preferred.

The residence times in the various stages of the process are in the range from about 5 to 30 minutes for a V16" thick lay-up, comprising about 60%-70% resin and about 40%-30% ber content. Generally, it will be stated that residence time is sufficient to attain the goal or condition sought in the particular section under consideration. Thus, proper gel requires quite exact residence; and this may well vary according to conditions and resin characteristics. Also, the temperature will be understood to be variable within limits to achieve the particular goal of a particular section. These naturally liow hand-in-hand.

In light of the foregoing, it will also be understood that a sufficient residence time in the molds will be established to provide the goal of that section.

Thus, the foregoing comments are meant to bring out the fact that the line speed is subject to some careful variation to provide proper residence within the full scope of invention. Also, temperatures and residence are carefully coordinated.

Fiber and resin contents As briefly mentioned above when discussing residence time, it was stated that the productts of invention can have resin content in the range of 60%70% More broadly this range can be extended to 20%-80% of the weight of the panel. When so operating, it will be evident that the liber content values will be the supplements. Thus, the preferred liber range is about 40%-30%; and the broad fiber range is about %-20%.

Cover films Regenerated cellulose or cellophane has been disclosed as the cover iilm for use in the foregoing embodiments of the invention. It has been found that the best grade obtainable is desirable. This is admittedly a cost factor, but because of the fact that it is the difference between commercial success and failure, the cost is fully justified.

The extended scope of invention, however, would include the use of other cover films. Actually, stainless steel foil or the like could be conceivably used and stripped from the product at the exit end of the forming molds for recovery and recirculation through the system. In 1000 ft. lengths, this would be entirely feasible. Also, acrylic cover films, silicone containing films and the like, could be used, so long as they were strippable from the cured resin and provided operability in accordance with the method set forth herein. Polyesters and polyoleins may be used also.

Three acrylic resin systems have been specifically mentioned in the foregoing description. However, although specific systems have been set forth, it is evident that these are subject to modification. Thus, the accelerator can be either partially or entirely added to the mix and degas kettle, or partially or entirely to the various mats that go into the wet lay-up.

It is also believed that the present invention is applicable to other heat polymerizable resins adapted to the production of panels. However, this statement is made knowing full well that gel table temperatures, top and bottom mold temperatures and post-cure oven temperatures, as well as line speeds and other factors will have to be adjusted to accommodate such other resin systems.

It is, of course, submitted that there is sufficient versatility to the procedural method of the present invention to encompass the operating techniques that may be essential in processing other polymerizable resins than the various acrylics.

It is thus evident that the present invention is applicable to the use of other resins, at least those of fiowable liquid formulation, in the production of panels on a continuous basis. The polyesters of the prior art, of course, come readily to mind. However, in view of the disadvantages inherent in these prior polyester products as discussed above, the likelihood of further production of those elements without some advance in technology as an aftermath of the impact of the acrylic panels of the present invention on the commercial market is highly unlikely. The invention in its many ramifications and great versatility is nevertheless to be understood to cover such a contingency.

Top mold modification Although the top mold has been described above as having the bottom formed as an actual mold surface, the broad scope of invention is in this instance extensible. Thus, the bottom of the top mold tank can be formed as a liat sheet the same as the top of the bottom mold. To this there can be detachably connected a mold sheet or caul sheet in the manner in which this was done in FIG. 4 relative to bottom mold 126. Thus the broad scope of invention encompasses readily replacable upper and lower molds for ease of shape change and of course minimum loss of product and materials because of short down time for change over.

Note that aluminum has been elected for the mold surfaces because of its high heat transfer. Within the broad scope of invention, however, this surface might be made of Teflon or other high temperature resistant resin. Also, within the broad scope of invention, a coating of Teflon or high melting wax or the like can be applied to the mold surfaces to provide greater lubricity for passage of lthe laminate. Actually, a Teflon coated, galvanized iron sheet might be used in some instances.

It is also within the extended scope of invention to make the'lower mold surface liexible. In this sense, the lower mold surface might be part of a pressure tank and pressurized fluid used to press the bottom mold uniformly into contact with the laminate. Also, the top tank could be similarly pressurized for accurate control and exact conformity to or with the bottom mold.

Extension of nip construction The nip disclosed in the foregoing specification has been described as being formed by two corotatable cylindrical rolls or equivalent structures. However it is believed that the invention can be logically extended to 18 include two fixed cylindrical surfaces positioned similarly to the roll surfaces.

By so operating, such surfaces would be coated with a suitable lubricant to allow passage of the cover film by sliding movement. This would permit the cover film to carry the mats in unstressed condition in the manner described relative to the operation of FIGS. l, 14 and others.

Mats made from continuous fibers have been discussed generally. However, the extended scope would include chopped strand mats. Also, the extended scope would include nonreinforcement type materia-ls, including glass flakes, fillers, other fibrous materials, etc. Thus, the invention is not limited to structural-type panels requiring reinforcement; it is also applicable to decorative panels using color and filler only.

In broader aspects, therefore, the invention relates not only to panel formation but also to a novel apparatus and method of handling acrylic resin systems.

ADVANTAGES AND CONTRIBUTIONS TO THE ACT In view of the foregoing, it will be obvious that a novel product, continuous production line and operating technique are contributed to the art by the present invention. These are characterized by the following features:

(l) Unique wet lay-up formation on a continuous basis, utilizing vertical nips and edge sealing by a mastic ribbon. See the left side of FIG. l of the drawings. Improved mat wet-out and degassing are provided and with negligible fiber wash and mat distortion.

(2) Continuous curing by movement through fixed molds for the production of acrylic resin products of improved durability. Therefore, better products of reduced cost are provided for the consuming public by the invention.

(3) The present system is characterized by fixed supports in the form of: (a) lixed run-out table; (b) fixed gel plate; and (c) fixed forming molds.

(4) Totally integrated raw fiber to final panel formation. A truly creation-to-consumer concept. The benefts to both manufacturer and consumer are indeed substantial, to-wit:

(a) Complete elimination of interim handling of components between fiber formation and actual panel completion. This increases the manufacturers profit by eliminating interim handling, labor costs and simultaneously enables him to reduce the cost to the consumer.

(b) A better quality controlled final product.

(5) Greatest flexibility of resin application both as regards: (a) the resin system; (b) resin application.

Component (a) is characterized by accelerator addition either to the resin at the mixing and degassing stage or to the reinforcement and surface mats. Addition of accelerator to the mats, providing precise acceleratorresin mixing at the exact point of use, has been described above. This provides extended pot life to the raw resin syrup cutting down the necessity for operator diligence and obviating emergency dumping with waste of resin and other problems inherent therein.

In view of all of these ramifications, the versatility of the resin system is tmly demonstrated.

(6) Another important advantage is that of improved uniformity of cross section throughout the finished product. The gel production in the flat reduces run during later shaping. In a process where the wet resin is placed on a curing mold, runs are bound to result.

We claim:

1. In apparatus for producing a molded synthetic resin panel from a fibrous reinforcement mat and a polymerizable resin syrup.

means defining a nip of generally V-shaped and elongated configuration,

means for linearly feeding a first cover film and a fibrous mat into said nip,

means for linearly feeding a second cover film into said nip into converging relation with said mat to form a sandwich,

and means for depositing liquid resin in saturating relation into said mat during passage of the mat through said nip,

means for radiating the so-formed lay-up to provide humidityk compensation and pliability in the cover lms,

means for gelling said resin, comprising a heating surface to contact the lay-up,

means for maintaining a heated material in contacting heat-exchange relation with said surface at a ternperature suitable to polymerize the resin in said layup to a gel, and said material being effective to absorb f exothermic heat of polymerization from the resin and control the gelation,

spaced molds defining a contoured mold space to receive the gelled lay-up,

means for maintaining a heated material in contacting heat-exchange relation with said molds at a temperature suitable to further polymerize the resin in the lay-up to a substantially solid state, and said material being effective to absorb exothermic heat of polymerization from the resin and control the mold polymerization,

means biasing said molds towards one another with sufficient force to mold the gelled lay-up,

an oven to receive the molded panel,

means heating said oven to a temperature sufiicient to post-cure the molded panel,

and means for moving said lay-up successively from said nip to said conditioning means, said gel means, said molds and then through said oven.

2. In apparatus for producing a molded synthetic resin panel,

means for forming a strand from a plurality of continous fibers of heat-softenable material of appreciable strength in tensile, l

v Re. 12,416

means for forming said strand into a mat of random interfelted structure,

means for forming a wet lay-up, comprising a pair of rolls having their axes parallel and positioned in a horizontal plane and with their -peripheries in adjacent, closely spaced relation forming a vertically disposed nip,

means feeding a first carrier film supporting the fibrous mat in at least partially lapped relation over one of said rolls into said nip,

means feeding a second carrier film in at least partially lapped relation over the other of said rolls and into said nip,

means for depositing liquid resin in said nip at a position spaced inwardly from the ends of said rolls,

means retaining said resin as a pool within said nip and between the ends of said rolls,

means for gelling the resin of the lay-up, comprising means for simultaneously heating the wet lay-up to a temperature sufficient to polymerize the resin to a gel and to absorb exothermic heat of polymerization from the resin during gclation to control the rate and degree of gel.

means for molding said gelled lay-up, comprising means defining a contoured mold to receive the gelled lay-up.

means biasing said mold against said gelled lay-up with suicient force to shape it,

means for simultaneously heating the mold to a temperature sufficient to polymerize the resin to a substantially solid state and absorb exothermic heat of polymerization from the resin and control the rate and degree of mold polymerization,

means for heating the molded panel to provide postcure,

and means forv moving the lay-up successively to said gel means, saidmold means, and then said post-cure means.

References Cited UNITED STATES PATENTS' BENJAMIN A. BORCHELT, Primary Examiner S. C. BENTLEY,Assistant Examiner U.S. Cl. X.R. 

